Hydrocarbon conversion apparatus



March 1, 1960 s. R. sTlLEs ET'AL 2,927,009

HYDRocARBoN CONVERSION APPARATUS 2 Sheets-Sheet l Filed Oct. 20. 1953 March 1, 1960 s. R. STILES ET AL 2,927,009

HYDROCARBON CONVERSION APPARATUS Filed 001'.. 20, 1953 2 Sheets-Sheet 2 United States Patent() 2,927,009 HYDRocARBoN CONVERSION APPARATUS Samuel R. Stiles, Cresskill, and James Warburton, Rutherford, NJ., and John M. Black, Plandome, N.Y., assignors to The M. W. Kellogg Company, Jersey City, NJ., a corporation of Delaware Application October 20, 1953, Serial No'. '387,118 9 Claims. (ci. zs-zss) 2,927,009 Patented Mar. l, 1 960 aration section without reaching the` mixing means of any subsequent zone.

Concurrently with the allcylation reaction, there is a condensation reaction of the olefin hydrocarbons in the sulfuric acid which may be termed "hydropolymeriza tion. The condensation products of `this reaction are undesirable as they reduce the yield of desired products, accumulate in the acid phase andin the emulsion, and

impair the catalytic activity of the acid. The hydropolymerization reaction rate increases with the concentration of the olein hydrocarbon reactants and the reaction temperature. To improve the eiciency, both with regard to the alkylate product and the sulfuric acid ernployed, the alkylation reaction is usually carried out at comparatively low temperatures and at low concentrations of olen hydrocarbon reactants. Thus itis portant to maintain in the reaction` zo'ne a relatively high concentration of isobutane and as high a ratio ofisobutane to olefin reactants as is practicable. To thisY end `an isobutane to olen feed rate ratio of about 6-l0:l

, and higher is commonlyemployed.

of a liquid catalyst which is immiscible with the reactants, i

it is necessary to secure intimate mixing ofthe catalyst and the reactants to thereby form and maintain an emulsion in which either the reactants or the catalyst constitutes the continuous phase. In the alkylatiou of hydrocarbons, whichiwill be referred to as illustrative of the reactions to which` the present invention isapplicable, it

` is necessary to effect intimate mixing of the hydrocarbon reactants and the acid catalystito obtain thebenetsof the catalytic action ofthe acid catalyst; the degree of mixing of the hydrocarbons `and acid is an important factor in determining the rate of conversion and the overall eiiiciency of the operation. In the alkylation of isoemulsion apparently have van important effect on the rate` at which the reaction occurs` at the surface of the isobutane droplets. Such aprocess is operated infthe prior'` practice with a View to forming `and maintaining a proper body of emulsion so as to assure high overall efficiency.

Ordinarily a plurality of series arranged communicating reaction Vzones are used, into the first of which the acid .and the bulk of the isobutane `are introduced for series `tlow through thezones while the olefin feed is supplied in parallel streams `to the respective reaction zones and emulsied `by appropriate mixing means therein. The overflow from one reaction zone passes to the next reaction zone; from the last reaction zone the product over-,i

v -end of the zones are in open communication, lighter Lmaterials can flow from any one zone tothe product sep- It has been found in accordance with the present invention, that the-reaction between the isoparaiin hydrocarbons and the `olefin hydrocarbons is driven preponderantly in the direction of .the alkylation reaction `and the undesired products, due to the hydropolymerization reaction, reduced to a minimum if a high isoparain-olefin ratio is maintained in the `region of introduction and intermixing ofthe olefin hydrocarbon into the isoparain hydrocarbon-acid emulsion; isoparain hydrocarbon-oleiin ratios in the introduction and intermixing regiones low as 200:1 willgiveimportaht improvements in the results, `but the best results are obtained with ratios in the order `of 400:1 and higher. i

it is an object of this invention to provide a process and apparatus for effecting liquid phase alkylation of isoparatiin hydrocarbons with olen hydrocarbons in the presence of an acid catalyst in which the acid catalyst and the isoparafiin hydrocarbon reactants are progressed in series ow through a plurality of reaction zones, whilethe olen hydrocarbon reactants are supplied in parallel flow to the plurality of reaction zones to be intimately intermixedthereat substantially as supplied with the isoparain hydrocarbon and th'eacid `catalystllo'wing through the respective reaction zones, the seriesilow of the isoparaflin hydrocarbon and the acid catalyst beingfrom the bottom to the top of a respective zone *and `from` thenceto the bottom ofthe next zone, the mixing means being'located at the bottom of each of said zones so that 'n'o material can pass through anyone of said `zones without passing through the respective mixing means and traversing the full length of said-zone; `said mixing means furthermore inducing a suiiciently high flow rate in the region of olefin hydrocarbon introduction to establish thereat a desired high isoparaiiin hydrocarbon-olefin hydrocarbon ratioi It is also an object of this invention to provide a process and apparatus for ,effecting liquidphase alkylation ,of isoparatin hydrocarbons in which the acid catalyst and the isoparaiin hydrocarbon reactants are progressed in series tiow through a plurality of mixing and reaction zones, while the Iolen .hydrocarbon is supplied inparallel flow to each` of said zones; said mixing zonesbeing` separate and maintained at pressures suiicient for evaporation of hydrocarbon supplied to the feed for', `autop refrigeration of said reaction zones, said pressures being process by reference to embodiments of theapparatus of the invention.` VItjis to be understood, however, the invention is `not limited by reference'to the specific modimixing section 15.

cations illustrated by the drawings but is capable of other modification within the scope of the invention.

In the drawings, Fig. 1 is a side view partly in section illustrating one embodiment of the apparatus of the invention;

Figs. 2 and 3 are sectional Views of the apparatus of Fig. l taken' on lines 2 2 and 3 3 respectively;

Fig. 4 is an enlarged view partly in section of the mixing device employed;

- YFig. 5 is a sectional view taken on line 5 5 of Fig. 4; and

Eig. 6 is a diagrammatic view of the apparatus set up for carrying out the knovel process of the invention. Referring to Fig. 1,' the reactor 10 may be of any convenient shape and lsize but is preferably in the form of auclosed ended cylindrical or approximately cylindrical tankas' shown. The vreactor 10 is divided by means of a baffle or deilector plate 13 into a reaction zone 11 and afsettling zone 12. The reaction zone 11 is conveniently of approximately the same volume as the settling zone 12 but this ratio is subject to wide variation. ,y The reaction zone 11 is divided into an entrance sectio'n 1-4 and a plurality of mixing sections, three mixing sections 15, 16 and 17 being included in the reactor 10 shown but two, or more than three, may be employed as operating conditions require. The entrance section 14 is at one end of the reactor and is defined by the dished head 18 and the circular partition 19. The par- Vtition 19, as shownin Fig. 2, has a bottom section thereof removed to provide a port 20 through which material in the section 14 may pass for entrance into the bottom of the mixing section 15. The periphery of the partition 19 is united, as by welding, to the walls of the reactor 10 and may have stiffening and reinforcing means united thereto, as for instance the rectangular bars 21 which are welded to either or both sides of the partition 19. Mixing section is defined by the cylindrical walls of the reactor 10 and has one end closed by the partition 19` and the other `end by the partition 19. The weir partition 22 is provided adjacent the partition 19. As shown in Fig; 3, the partition 22 is likewise circular but has a much larger section removed from its top and is arranged to form a Weir which establishes the material level in the mixing chamber 15 and thus controls the outflow of materials therefrom. Ifrdesired Va weir notch, not shown, may be formed in the to'p of the partition 22 for more accurate material level control. The periphery of partition 22 is likewise united, as by welding, to the walls of the reactor 10 and may also have stiffening and reinforcing means united thereto, as for instance the rectangular bars 23 which are welded to either or both sides of the partition 22. The bars 21 and 23 may also be used as a spacing means as will be explained hereinafter. A rectangular plate 24 having a hole 25 therein has one end united to the bottom edge of the partition 19 and its sides united to the cylindrical wall of the reactor V10, as by welding, to provide a passageway 26 for llo'w of material from the bottom of the entrance chamber 14 .toV substantially the middle region of the bottom of the The hole 25 may be circular or rectangular, as preferred. A small plate 27 in the form o'f a section of a circular disc is united to the walls of the reactor 10 and to the end of the rectangular plate 24 to close'the end of the passageway. 26 so that all the material that enters the port'20 can only pass into the mixing chamber 15 through the hole 25. If deemed .,jnecessary a small hole, notv shown, may be drilled through the plate '27l adjacent thebottom thereof for drainage purposes, otherwise, no holes ,or ports are provided in any of the partition members mentioned.

The construction of the mixing section 16 is substanftially identical to that of the section 15, the correspondflows the top edge of the partition 22, then ows down through the down-flow passageway 28, formed between the partitions 22 and 19' to enter the po'rt 20. The bars 21 and 23 can be made of such a width that the exposed edges thereof bear against the respective opposed par-- tition 19 o'r 22 and thus maintain the spacing between: the partitions 19 and 22. The mixing section 17 is similar to the section 15 and the corresponding parts thereof have been designated by double primed numerals. The mixing section 17 differs from the mixing sectio'ns 15 and 16 primarily in that the downstream end thereof is defined by the coalizer partition 29 and the deflector plate 13 and in that it is in open communication at its top with the settling zone 12.

The deflector plate 13 is united to the walls of they reactor 10 and extends from a level considerably above the top of the partitions 22 and 22 to a level somewhat below the top of the settling zone partition 30, to behereinafter referred to, so that all of the liquid material that passes from the reaction zone 11 to the settling zone 12 must pass through the coalizer 29. The coalizer partition 29 is defined by the spaced partitions 31 and 32. The space between the partitions 31 and 32 is illed with a suitable packing 33 such as carbon Raschig rings, or crushed siliceous rock which is inert to the reactants. The partition 31 is solid, is substantially the same as and corresponds to the weir partitions 22 and 22' and establishes the liquid level in the mixing section 17. The partition 32 is perforated.

Each of the mixing sections 15, 16 and 17 has a mixer provided therein. The mixers 35, 35a and 35h are identical in construction so that the description of one of them, the mixer 35, will suliice for all. The mixer 35, shown in detail in Figs. 4 and 5, is mounted in a circular opening 36 formed in the top of the section 15 and with its lower inlet end spaced from the plate 24 and overlying the hole 25 therein. The hole 25 is smaller than the inlet of the mixer 35. The relative areas of the inlet of the mixer 35 and the hole 25 and the spacing of said inlet from the plate 24 are so proportioned and adjusted that all the material supplied to the hole 25 enters said inlet while permitting entrance of desired quantities of material through the space between the hole 25 and said inlet. To this end also, the hole 25 may have an upwardly extending rim or lip united to its periphery (not shown). The walls of the opening 36 are built up to form a flange 37 of appropriate size to support the mixer 35 while in operation. Ther mixer 35 is suspended from an annular ilange ring 38 whose outer peripheral portion rests on the face of the flange 37 and is fastened thereto by arcircular series of bolts. Extending downward from the ange ring 38 and fastened rigidly thereto, as for instance by a circular series of bolts, is a cylindrical shell 39 of a diameter to t loosely within the opening 36. The shell 39 extends downwardly into the mixing section 15 a substantial distance and is closed at its lower end by an annular tube sheet 40 which carries a circular series of tubes 41 extending upwardly therefrom.

An impeller housing 42 is positioned beneath the tube sheet 40. The shell 39, the tube sheet 40 and the impeller housing 42 are fastened together into a unit by means of a circular series of studs which enter tapped holes in a flange at the lower end of the shell 39 and carry suitable nuts threaded thereon which bear against a ange formed at the periphery of the impeller housing 42. The housing 42 is preferably formed as a casting and includes internal deector webs 43 connecting the housing 42 to a bearing supporting structure 44 which is hollow at its upper end and is provided thereat with ports 45. A suitable impeller 46 provided with blades 47, is mounted on the central shaft 48 which is journaled in the structure 44 and extends vertically therethrough.

The central opening of the flange ring 38 is covered by the peripheral flange of the hollow member 49, said peripherlllatge and the tiange ring 38 being united by a circular series of bolts as shown. The hollow member 49 is conical-in shape and includes webs which support the bearing structure 50 for the upper end of the shaft 48. A nozzle construction 51 is provided for supplying one of the reactants to the hollow of the member 49. A vertical tubular member 52 surrounds the shaft `45 and connects the hollow of the member 49 to the hollow upper end of the bearing support structure 44 so thatthe reactant that is introduced through the nozzle 51 may flow from the hollow of the member 49 through thetubular' member 52 into the hollow of the structure 44 to be discharged through the ports 45 into the outlet ofthe impeller housing 42. As an alternative construction, the ports 45 may be eliminated and in their stead a transverse bore may be prow vided in each of the deflector webs 43, said transverse bores being placed in communication through suitable bores with the hollow upper end of the member 44. The reactant may' flow out of the transverse bores through a plurality of small holes in the face of the detlector webs -43 or throughholes in the slip stream end of the webs `43(this alternative construction is not shown).

The upper end ofeach of said tubes 41 terminates a substantial distance below the flange ring 38 so that sufficient space is provided for the reversal of direction of llow of the material propelled through the tubes 41 by the impeller 46. After the tlow reversal just mentioned, the propelled material flows downwardly in the space between the tubes 41,` the tubular member `52 and shell 39 to exit from the series of elongated holes 53 located adjaeentthe bottom end of the shell 39. A series of comparatively small gas vent holes are provided adjacent the top end of the shell 39 to prevent gas accumulation in the ow reversing space between the upper end of the tubes 41 and the flange ring 38. The tubes 41 may be fixed against lateral movement by the provision of suitable connections 54 arranged as needed along the length of the tubes 41 to maintain them in proper space relation as shown in Fig. 5. t

For the lubrication of the bearings in the structure 44 a suitable connection 55 is provided; any suitable lubricant maybe employed. Similarly, the upper bearing structure 50 may be lubricated through a suitable connection 56. a

Any suitable meansimay be provided for driving the shaft 48 and the impeller 46. Suitably, the power necessary may be applied through gear reducing means which i are assembled in the housing 58 and which are in turn acid section 62 and product section 61. The partition 30 isapproximately `semi-circular in shape and united to the walls of the reactor 10, as by welding. The top edge of the partition 30 is at a somewhat higherV level than the top edge of the opposed perforated plate 32 of the coalizer 29. The reacted material as it passes through the coalizer 29 separates into acid and liquid hydrocarbon and layer separation of the two takes place in the acid section 62. The lighter liquid hydrocarbon being the top layer, overows partition 30-and collects in the product section 61 while the acid settles in the bottom of theY acid section 62. The liquid hydrocarbon product is removed through the pipe nozzle 63 in the bottom of the product section 61 for further processing. The acid 1s removed through the pipe nozzle 64 in the bottom of the `acid section 62.

Each section 15, 16, 17,61 and 62 is provided4 with `departing from the invention.

,6 a manhole `65 to render said sections accessible for inspection and repair. Each manhole 65 is closed by a suitable cover, as shown, during operation of the reactor 10. The sections 15, 16, and 17 are also each provided with a nozzle 66 to facilitate the removal of residual maerial from the respective sections during cleaning, etc. The section 14 is provided with a nozzle 67 through which the isoparatiin hydrocarbon may be introduced into the system. Section 14 as well as sections 15, 16 and 17 are each provided with a nozzle 68. The nozzles 68 may be manifolded through suitably valved lines, as shown for instance in Fig. 6, so that the tops of the sections 14,15, 16 and 17 are placed in communication for gas flow at controlled rates from the sections 14, 15 and 16 into the section 17 and consequently into the zone 12.

By suitable control of the gas ilow out of sections 14,15

and 1\6,\thes`e sections may be maintained under any preferred pressure arrangement, however, the pressures in the sections 14, 1S and 16 should progressively diminish but all must always be higher than the pressure in section 17 so that the pressure differential will be effective to facilitate the series flow of the reactants through the zle 69. A pipe extends from the nozzle 70 to assure theA return of the material to the acid section 12 andbeneath the liquid level therein. Section 15 also includes a nozzle 71 through which the acid catalyst is supplied to the reactor 10. i

The reactor 10 may be variously modified without Thus, in place of the specic type of mixing means shown and described, other suitable types may be used. Also, reaction zones each including two, or more mixing sections and asettling section, may be disposed on each side of a single product zone and all three zones` included in a singlevessel.

In carrying out liquid phase reactions in the presence of a liquid catalyst which is immiscible with the reactants, as for instance in the alkylation Vofisoparalfin' hydrocarbons in which sulfuric acid is employed as the catalyst, and using the reactor 10 above described, the isoparaiiin hydrocarbon feed which comprises the isoparai'lin hy drocarbon recycle feed and any fresh isfoparain hydrocarbon feed required and not supplied by the alkylating hydrocarbon feed, after having the recycle acid catalyst added to it is` introduced into the entrance section 14 through the nozzle 67, while the fresh acid catalyst feed is introduced into the bottom of section 15 andbeneath the hole 25 in the plate 24 through the nozzle 71. `The isoparaflin hydrocarbon feed may comprise a single iso- `paratiin hydrocarbon or a mixture of such hydrocarbons or a mixtureV comprising one or more isoparaiiin hydrocarbons and one or `rnore normal pmafn hydrocarbons; Alternately the section 14 may be eliminated and the isoparaiiin `hydrocarbon feed as defined above and without the addition of the acid catalyst recycle, supplied directly to the inlet of the mixer 35 throughtthe nozzle connection 71 While the recycle acid catalyst and the fresh acid catalyst after being joined are supplied to the bottom of the section 15 through the nozzle 66. It is also possible, though not preferable, when the section 14 is eliminated, to locate the nozzle 67 on the axis of the mixer 35 and the nozzle 71 adjacent thereto and beneath the plate 24 so that the isoparain and the acid catalyst enter the reactor 10 at substantially the same location at the bottom` entrance to the mixing section15.

- The alkylating hydrocarbon feed which Vmay be a single olen hydrocarbon, or a mixture of olefin hydrocar "7 bons, or a mixture of one or more olefin hydrocarbons and one or more isoparatin hydrocarbons which may also include one or more normal parain hydrocarbons, is divided into three separate parallel streams and a separate stream enters each of the mixers 35, 35a and 35!) through the respective nozzles 51. The isoparafn hydrocarbon content of the alkylating hydrocarbon feed may be less than, or equal to, or more than, the quantity required for alkylation reaction with all of the olefin hydrocarbon present. The alkylating hydrocarbon feed introduced into the nozzle 51 will flow downward through the tubular member 52 to exit out of the ports 45 at the outlet of the impeller 46 to be admixed thereat with the acid catalyst and isohydrocarbon feed pumped by the impeller blades 47. 'Ihe impeller 46 is operated at relatively high speeds in a manner to impart high velocity to the liquid presented to it so that it rapidly and intimately intermixes the acid catalyst, the isohydrocarbon, and the alkylating hydrocarbon and forms therefrom an emulsion. The emulsion is further formed or maintained by the high velocity flow thereof through the tubes 41, by the rapid change in direction in the space above the tubes 41 and the ow through the comparatively restricted passages between the tubes 41, the shell 39 and the tubular member 52. The ow of the emulsion at high velocity and in the manner described, produces shearing eiects whereby the droplets of the emulsion, which ordinarily contain the isoparain reactants, are continuously subdivided to present new surfaces for reaction and to present a. large area of Contact between the phases. The constant shearing of the droplets provides continuons presentation of fresh isoparain reactants at the surfaces of the droplets, which is the location apparently at which reaction occurs. The mixing of the catalyst and reactants, as accomplished by the mixers 35, 35a and 35h also results in the frequent replacement of the layer of acid catalyst immediately adjacent the droplets that contain the reactants. The capacity of the impeller 46 is greatly in excess of that required merely to pump the acid catalyst, the isohydrocarbon and the alkylating hydrocarbon supplied through the nozzles 71 and 67 and the ports 45 respectively through its respective mixing section so that a rapid recirculation of the emulsion within its respective mixing section takes place and the mixers 35, 35a and 3517 are positioned suiciently above the re spective plates 24, 24 or 24" to facilitate the recirculation action. The capacity of each of the mixers 35, 35a and 3511 is such that material presented to each of them is recirculated fteen, or more, times before it leaves the respective reaction section 15, 16 or 17.

By maintaining a proper pressure relation between the sections 14, 15, 16 and 17, the emulsion overflows the baie 22 in section 15 to flow downward through the passageway 28 and into the passageway 20', from thence to tiow through the hole 25 and to be presented to the mixer 35a at a rate substantially equal to the combined rate of acid catalyst and hydrocarbon input. The mixing and recirculation action is repeated in mixing section 16 but with the admixture of a fresh supply of alkylating hydrocarbon, and again emulsion flows over the weir 22' to the holey 25 and to the bottom of the mixing section 17 at a rate substantially equal to the combined. rate of the acid catalyst and hydrocarbon input. In the mixing section 17, the mixing and circulating action is again repeated and again with admixture of a fresh supply of alkylating hydrocarbon.

The mixing section 17 is in open communication with the settling zone 12 and at the same pressure as the settling zone 12, hence ow of material from the mixing section 17 to the acid section 62 does not take place because of a difference in static pressure but rather because of different pressure heads. To this end, acid catalyst and product are drawn off through nozzles 64 and 63 respectively, at Isuch rates as to maintain the liquid level in the product section 61 below the liquid level in the acid section 62 and the liquid level in the acid section 62 below the emul sion level in the mixing section 17. The top of the deflector baffle 13 is at such a level as to prevent normal as well as accidental iiow of the emulsion in the mixing section 17 thereover.

The emulsion leaves the mixing section l17 over the top of the Weir partition 31 and flows through the coalizer 29 for ow into the acid section 62 of the settling section 12. In owing through the coalizer 29, the emulsion is broken down into two continuous phases. In the acid section 62 the lighter hydrocarbon separates as a layer on the heavier acid catalyst to overow the partition 30 into the product section 61 wherefrom it is withdrawn throughvthe nozzle 63 for further processing. The acid which collects in the bottom of the section 62 is withdrawn in part for recirculation and in part forV reconditioning.

The reaction described is exothermic and in order to maintain the desired temperature range, the sections 14, 15, 16, 17 and the zone 12 must be cooled. The necessary cooling efect may be obtained in various Ways as by employing various devices, such as coils through which a cooling medium is circulated, etc. The reaction and the apparatus used in carrying it out are such, however, that auto-refrigeration is ideally suited. The isohydrocarbon input is vaporized in the various sections men-A tioned at sufficient rates at the operating pressures'to produce a refrigeration eiect sulicient to maintain the predetermined temperature.

When the apparatus and process of the invention are employed in carrying out exothermic reactions in which the heat developed causes vaporization of a portion of the liquid reactants during the process, the method of introducing the alkylating hydrocarbon feed to the mixers 35, 35a and 35b is particularly advantageous. For example, in the alkylation of isoparatm hydrocarbons with olen hydrocarbons under conditions of temperature and pressure permitting continuous vaporization of unreacted hydrocarbons for temperature control purposes, it is particularly advantageous to introduce the olen reactants at the outlet or high pressure side of the impeller 46. ln view of the relatively low concentration of olens maintained in the reactor 10 as a whole, it is evident' that the alkylation reaction, and the development of exothermic heat of reaction, are most intense at the point where the olen reactants are admixed With the isoparafiins and the acidV catalyst. The vaporization of the mixture at that point, therefore, is relatively high. Consequently, the introduction of the olefin feed through the' ports 45 into the high pressure side of impeller 46 has the advantage of permitting vaporization without interferring with circulation. The introduction of the fresh feed in this manner also accomplishes substantially instantaneous and complete mixing of the olefin reactants with the acid and the isoparaiiins discharged from the impeller and the resulting mixture is then immediately driven through the tubes 41 to promote intimate and effective contact of reactants and catalyst. Furthermore, since each impeller 46 is arranged to recirculate the acid catalyst and the isoparain content of its respective mixing section many times past the ports V45 through which the olefin reactants are supplied, this results in effect in multiplying the ratio of isoparain hydrocarbon to olen hydrocarbon many times. Thus, if the ratio of isoparain hydrocarbon to olefin hydrocarbon supplied to the reactor 10 is in the order of about 4:1, Kthe ratio for each mixing section Will be about 10:1. If each impeller 46 recirculates the content of its respective mixing chamber 15 to 40 times the mentioned, ratio is increased to the order of to 400 to l. The olen hydrocarbons are thus immediately upon introduction into the reaction zone, subjected to optimum conditions for promoting alkylation reactions with a minimum hydropolymerization and the objectionable products v thereof.

The heat of the alkylation reaction and the heat developed in the mixing operation necessitates some means 9 for cooling the reaction zone to maintain the reaction temperature at the desired level. Heatmay be extracted from theb'ody of liquids i1 the reactionA zone by indirect heat 'exchange with an external refrigerating means. Preferably, however,` internalrefrigeration is effected by permitting continuous evaporation of unreacted hydrocarbons which are withdrawn from' the mixing sections, condensed, cooled, and returned for further treatment. Isobutane available for charge material to an alkylation process ordinarily occurs in mixtures which contain subf stantial quantities of `normal butane. A substantial proportion o'f propane also may be present. inasmuch as Athese hydrocarbons, together with the isobutane,` con stitute the lowest boiling constituents in this portion of the reaction mixture which are heated by the exotherrnic reaction, refrigerating `the reaction mixture by evaporation results in the separation from the reaction mixture of'vaporized hydrocarbons consisting of isobutane, nor- Amail butane and propane and predominating in isobutane.

Such a mixture is condensed and returned to the reaction zone` 11. Suitably all or a portion thereof may be fractionated to separate propane to be discarded. This method of eliminating propane is advantageous because the mixture thus treated `has a higher concentration of propane than any other hydrocarbon ymixture in the system. Suicient propane is thus eliminated to balance the `amount introduced into the system as fresh feed.

`The quantity of` propane maintained in the reactionV zone 11 may be regulated to provide the degree of evaporation necessary to abstract the heat of `reactionat the sired to conduct the reaction.

t 'Iheschematic showing of Fig. `dindicates how the ap,- paratusdescribed intdetal and shown in Figs. 1 to 5 is hoked up in a catalyst installation. `In Fig. 6, the ar in a ,process in which the reaction mixture is cooled by,

internal refrigeration in the manner described above. The-.sections 14, 15, 16 and 17 are in communication at the upper portions thereof by a piping arrangement which interconnects the nozzles 68 `of the respective sections. The piping arrangement includes suitable valving adjacent each of the nozzles 68 so that the dow out of the individual sections may be independently controlledand any predetermined pressure pattern established and maintainedi. `Thenozzle `69 at the `product end of the settling zone 12 Ais connected through suitable piping to the refrigeration system. This system includes `a pumpwhich withdraws vapors` through the nozzle 69, `compresses them, and then passes them to a heat exchanger wherein they are condensed and from whence they are passed to a collection drum. A portion of the condensed gases f isreturned to the reactor through the isobutane recycle line while the remainder is passed to the depro`` panizer whereat propaneA is removed to Ybalance the amount added to the system by the fresh hydrocarbon feed or feeds. `After depropanization, the stream is returnedtoisobutanerecycle feed and passed by suitable piping to the nozzle 67 "for admission to the entrance `section 14. The refrigeration system includes a drum, between the `nozzle 69 and the pump, in which any liqconditions of temperature and pressure at which it is vdei the nozzle 64. A portion of the withdrawn acid is re moved from the system as spent acid while another portion is returned as recycle acid with the isobutane recycle. through the nozzle 71.` The product is removed from the product section 61 through the nozzle 63 and conducted through suitable piping to the product treating system.

In the alkylation of isobutane with butenes, or propylenes, or amylenes, or a mixture of two ormore of these oleiins, the olefin feed is divided, as shown in Fig. 6, into three more or less equal streams and passed to the mixers 35, 35a and 35h. The olefin feed usually vreadily available in a refinery for the alkylation of isobutane, includes both paraffin and olefin hydrocarbons, and of the parafiin hydrocarbons, both the iso and the normal forms; the hydrocarbons in the olefin feed range rom C2 `to C5 with the olefin contentmgenerallyrmade up of propylene and butene, isobutane is the only isohydrocarbon present. The isobutane content of the olefin feed usually approximates that required to react with all of the olefin hydrocarbons present. Thus, the isobutane feed is largely a recycle feed and is provided in such quantity as to maintain the preestablished isobutane to olefin ratio. This ratio is usually in` the order of 10:1 in individual mixing chambers, in accordance with the pfesent invention isobutane to olefin ratios in the orderof 8:1 for the individual mixing sections and in the order `of 3:1 `for the whole reactorl are preferred. The isobutane ,feed usually readily available in a refinery contains a mixture of normal and isoparafn hydrocarbons ranging fromethane to pentane and including propane and normal'butane in substantial proportions. The acid .catalyst may be supplied at rates -to maintain an acid tohydrocarbon ratio of as low as 1:1 but higher ratios in the order of 2:1 are preferred and can efficiently be handled in the method of the present invention. Y t

The isobutane recycle, the olefin feed, the fresh acid and the recycle acid are introduced intothe system and serially passed through the mixers 35, 35a and 35b to form an emulsiony and to` promote the alkylation reaction,`

as described heretofore. The action in the mixers 35 to 35a and 3511 circulate the content of their respective mixing sections past the respective olefinfeed inlet at such speed as in effect to increase the ratio of isobutane to olefin to the order of :1 and more, so that the reaction takes place with a minimum formation of objectionable compounds due to hydropolyrnerization The lighter constituents of the isobutane recycle feed vaporize in the `sections 14, 15, 16 and 17 to cool the content of the respective sections and to maintain a preestablished low temperature, usually 35 F. Byadjustment of the valve means in the piping through `which the `yaporsflow out of `the sections 14, 15, and 16, desired pressures may be maintained in the respectivemixing sections. Thus by way of example, the valving may be set to maintain a pressure of `8 prs.i. in the section 14, a pressure of 7 `p.s.i. in the section 15, a pressure of 6 p.s,.i. in the Section 16, and a pressure of .5 p.s.i.

Vthe section1`7 and the settling zone 12.

The vapor withdrawn from the sections 14, 15, 16 and 17 is compressed and then.` condensed. A portion of the condensed vapors is returned to the system with the isobutane `feed while the remainer is passed to the deprepanizer for removal of propane as required to balance the input of propane through the olefin feed. After depropanization said remainder is returned to 4theisobutane recycle. Fresh acid is added to the system at a suficient Fresh` acid feed is introduced to the section 15 Hydrocarbon: Barrels per day Ethane 4 Propylene 156 Propane 504 Isobutane 1 135 Butene 830 Normal butane 401 Pentane 14 The isobutane recycle was 9198 barrels per day made up of: v

Hydrocarbon: Barrels per day umane l 3 Propane 841 Isobutane 7485 Normal butane 852 Pentaue 17 The fresh acid feed was 133 barrels per day; 160 barrels per day of acid were removed from the system as spent acid while 345 barrels per day of acid were removed from the system and recirculated by admission thereof to the isobutane recycle line so as to be admitted with the isobutane recycle into section 14. A total of 505 barrels per day of acidwere withdrawn from the acid section 62. 5289 barrels per day were withdrawn from the production section 61. This material was made upof 1690 barrels per day of alkylate and 3599 barrels per day of material of a composition approximating that of the isobutane recycle. The latter material was returned to the system as part of the isobutane recycle.

In operating in accordance with this specific example, the temperature in the reactor was maintained at 35 F. To attain this temperature, the valves in the vapor lines which connect the sections 14, 15, and 16 to the section 17 were adjusted to maintain a pressure in the section 14 of 8 p.s.i., in the section 15 of 7 p.s.i., in the section 16 of 6 p.s.i., and in section 17 and the settling zone 12 of p.s.i. To handle the refrigeration load, 6553 barrels of liquids per day were evaporated and removed from the settling zone 12. The 6553 barrels per day of condensed vapors were composed of:

The mixers 35,y 35a and 35b were operated at such speed so that the ow therethrough past the olefin feed inlet was such as to multiply 'the isobutane to olen ratio approximately twenty-live times so that the apparent isobutane to olefin ratio was increased to the order of about 200:1.

12 The superior results obtained by the use of the novel apparatus and novel process are apparent from a consideration of the following comparative data, column l being data derived from conventional practice, while column 2 being data derived from practice in accordance with the present invention.

Production (Barrels/Stream Day) 1, 211 1, V201 Space Velocity (Volume of Acid/Volume of Olens/ Hr. 0.30 0.302 Isobutane in Reactor Euent (Liquid Volume Percent 51.3 53.1 External isobutane to Oleln Ratio per Mixing Section. 9. 0 9. 25 Internal isobutane to Olen Ratio at 2-1 Acid to Hydrocarbon Ratio 149 159 Lbs. Acid Consumed/gal. Alkylate Produced 1.89 1.35 Spent Acid Strength, Wt. Percent 94.4 95. 2 Rerun Yield of 388 F. End Point Alkylate Alkylat 85. 7 91.2 Octane Number: F-l Clear- Total Alkylnfn 92.8 Light Alkylate 93. 2 93.6' F-2 Clear- Total Alkylatn 91. 3 Light Alkylatr` 91.8 Octane Rating Performance Number:

F3+4.6 ce. TEL Light Alkylate 119 F-4+4.6 cc. TEL Light Alkylate 147 In the above F-1 is equivalent to Research Octane Knock Rating; F-2 is equivalent to ASTM Motor Octane Knock Rating; F-3 is equivalent to Lean Mixture Method Knock Rating for aviation gasolines; and F-4 is equivalent to Rich Mixture Method Knock Ratings for aviation gasolines.

Since many changes may be made without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not limitative.

We claim:

1. In apparatus for effecting liquid phase catalytic reactions, a reactor comprising an elongated, closed tank adapted in use to be substantially horizontally disposed, a plurality of spaced partitions closing the full cross section of said tank and subdividing internal space thereof into a plurality of separate, series arranged sections, each of said section closing partitions having a lower portion thereof cut away to provide a port for entrance from the section on one side thereof to the section on the other side thereof, plate means in each of the sections and on the other side of the respective section closing partition having one end united to the cut edge of the respective partition and its lateral edges united to the Walls of the tank to provide a passageway, barrier means in each of said sections united to the other end of the respective plate means and the walls of the tank to close said passageway, a hole in each of said plate means adjacent the middle region of the respective section to provide an inlet for the respective section, mixing means in each of said sections including a propelling device having an inlet mouth spaced from and overlying the inlet hole in its respective plate means, each of said sections including a level dening partition therein united to the walls of the tank and having its upper portion re moved to establish a desired liquid level, each of said level dening partitions being spaced from the contiguous section closing partition to provide a downiow passageway to the entrance port of the adjacent downstream section for material overowing the level defining partition.

2. The apparatus for effecting liquid phase `catalytic ,reactions as set forth in claim 1 in which, the furthest upstream one of said section closing partitions is spaced from one end of the tank by a distance sufficient to provide an admission section between said partition and said one end for materials employed in the catalytic reaction.

3. In apparatus for effecting liquid phase catalytic rei ing one end united to the cut edge of the respective disclike partition and its sides united to the vessel walls to provide a passageway, means united to the vessel walls and the respective plate for closing the end of said passageway in the respective mixing section, a hole in each of said plates for entrance into the respective mixing section from each passageway, mixing means mounted in each of said sections including a propelling device having an inlet mouth spaced from and overlying the inlet hole in its respective plate, and a liquid level establishing partition on 414 pelling device, liquid lev'el establishing means positioned in the top region of said mixing section, and conduit `means connecting said level establishing means to the inlet port in the downstream partition means of said mixing section, said partition means united to the walls `of said vessel to seal the respective sections whereby adjacent sections are in communication only through the respective conduit means and port.

8. Apparatus for effecting liquid phase catalytic reactions comprising a closed ended elongated vessel adapted in use to be approximately horizontally disposed, a plurality of transverse cross section closing partition means within said vessel and spaced along the length thereof dividing the internal space of said Vessel into a plurality of contigsaid one side of each of said disc-like partitions, said liquid t actions as set forth in claim 3, in which said disc-like partitions and said liquid level establishing partitions have reinforcing means united to the faces thereof.

5. The apparatus for effecting liquid phase catalytic reactions as set forth in claim 3, in which vertically disposed elongated bars are united to the faces of said disc-like partitions and said liquid level establishing partitions, said bars being of a suliicient width to contact the face of the partition opposed to the partition to which they are united whereby the width of said downow passageways are maintained as predetermined.

6. Apparatus for effecting liquid phase catalytic reactions comprising a mixing section having solid walls, a liquid propelling device in said mixing section, said propelling device including an inlet mouth positioned proximate the bottom of said section, an inlet port inthe bottom region of one of said walls, conduit means including an outlet opening underlying said inlet mouth and spaced therefrom connecting said inlet port to the region underlying said inlet mouth whereby material entering said inlet port ows through said conduit to said outlet opening and into said inlet mouth and liquid material in said mixing section enters the space between said inlet mouth and said outlet opening to flow intorsaid inlet mouth, an outlet port in the bottom region of one of said walls, liquid level establishing means in the top region of said section, and conduit means opening at said level establishing means and connected to said outlet port adapted to conduct liquid `overflowing said liquid level establishing means to said outlet port.

7. Apparatus for effecting liquid phase catalytic reactions comprising a closed ended elongated vessel adapted in use to be approximately horizontallydisposed, a plurality of transverse cross section closing partition means within said vessel and spaced along the length thereof dividing the liquid material entering the section directly to said inlet mouth, said outlet opening being vertically spaced from said inlet mouth to provide an` aperature therebetween for ow of liquid material from the mixing Vzone into the said inlet mouth for circulation through said prouous, series arranged mixing sections, each of said partition means having a port in the bottom region thereof providing an inlet for liquid material into the respective section, each of said mixing sections having a liquid material propelling device therein with an inlet mouth located adjacent the bottom of the section, conduit means connected to the respective inlet port with an outlet opening located directly beneath said inlet mouth to present the liquid material entering the section directly to said inlet `mouth, said outlet opening being vertically spaced from said inlet mouth to provide an aperture therebetween for flow of liquid material from the mixing zone into the said inlet mouth for circulation through said propelling device, means opening at the outlet side of said propelling device defining a llow path through which liquid reactants may be introduced for admixture with the liquid material circulated through said propelling device, liquid level establishing means positioned in the top region of said mixing section, and conduit means connecting saidl level establishing means to the inlet port in the downstream partition means of said mixing section, said partition means united to the walls of said vessel to seal the respective sections whereby adjacent sections are in communication only through the respective conduit means and port.

9. Apparatus for effecting liquid phase catalytic reactions comprising a closed ended elongated vessel adapted in use to be approximately horizontally disposed, a plurality of transverse cross section closing partition means within said vessel and spaced along the length thereof dividing the internal space of said vessel into a plurality of contiguous, series arranged mixing sections, each of said partition means having a port in the bottom region thereof providing an inlet for liquid material into the respective section, each of said mixing sections having a liquid material propelling device therein with an inlet mouth located adjacent the bottom of the section, conduit means connected to the respective inlet port with an outlet opening located directly beneath said inlet mouth to present the liquid material entering the section directly to said inlet mouth, said outlet opening being vertically spaced from said inlet mouth to provide an aperture therebetween for ow of liquid material from the mixing zone into the said inlet mouth for circulation through said propelling device, means opening at the outlet side of said propelling device defining a ow path through which liquid reactants are introduced for admixture with the liquid material circulated through said propelling device, liquid level establishing means positioned in the top region of said mixing section, conduit means connecting said level establishing means to the inlet port in the downstream partition means of said mixing section, said partition means united to the walls of said vessel to seal the respective sections, ow defining means opening into each of said mixing sections above the level establishing means therein to interconnect the top regions of said sections, suction means connected to the lowermost downstream mixing section effective to establish a predetermined pressure therein, and valve means in said ow defining means adjustable to maintain the remainder of said mixing sections at progressively higher pressures in the upstream direction to promote flow of liquid material from the liquid level establishing means of each upstream section to the inlet port of the respective adjacent downstream section.

References Cited in the le of this patent UNITED STATES PATENTS Houghton I une 22, 1937 McConnell Aug. 31, 1937 by., ma no -MN rg-...81.

UNITED STATES PATENT OFFICE CERTIFTCATE OF CORRECTION Patent No 2927 i1009 March l V 1960 Samuel R., Stiles et ala eprinted specification It is hereby certified that error appears in th d that the said Letters of' the above numbered patent requiring correction an Patent should read as corrected below.

Column 13@L line 6L, for "outlet" read e inlet Signed and sealed this 23rd day of August 1960 SEAL) Attest;

KARL H AXLTNE Attesting Officer ROBERT C. WATSON Commissioner of Patents 

1. IN APPARATUS FOR EFFECTING LIQUID PHASE CATALYTIC REACTIONS, A REACTOR COMPRISING AN ELONGATED, CLOSED TANK ADAPTED IN USE TO BE SUBSTANTIALLY HORIZONTALLY DISPOSED A PLURALITY OF SPACED PARTITIONS CLOSING THE FULL CROSS SECTION OF SAID TANK AND SUBDIVIDING INTERNAL SPACE THEREOF INTO A PLURALITY OF SEPARATE, SERIES ARRANGED SECTIONS, EACH OF SAID SECTION CLOSING PARTITIONS HAVING A LOWER PORTION THEREOF CUT AWAY TO PROVIDE A PORT FOR ENTRANCE FROM THE SECTION ON ONE SIDE THEREOF TO THE SECTION ON THE OTHER SIDE THEREOF, PLATE MEANS IN EACH OF THE SECTIONS AND ON THE OTHER SIDE OF THE RESPECTIVE SECTION CLOSING PARTITION HAVING ONE END UNITED TO THE CUT EDGE OF THE RESPECTIVE PARTITION AND ITS LATERAL EDGES UNITED TO THE WALLS OF THE TANK TO PROVIDE A PASSAGEWAY, BARRIER MEANS IN EACH OF SAID SECTIONS UNITED TO THE OTHER END OF THE RESPECTIVE PLATE MEANS AND THE WALLS OF THE TANK TO CLOSE SAID PASSAGEWAY, A HOLE IN EACH OF SAID PLATE MEANS ADJACENT THE MIDDLE REGION OF THE RESPECTIVE SECTION TO PROVIDE AN INLET FOR THE RESPECTIVE SECTION, MIXING MEANS IN EACH OF SAID SECTIONS INCLUDING A PROPELLING DEVICE HAVING AN INLET MOUTH SPACED FROM AND OVERLYING THE INLET HOLE IN ITS RESPECTIVE PLATE MEANS, EACH OF SAID SECTIONS INCLUDING A LEVEL DEFINING PARTITION THEREIN UNITED TO THE WALLS OF THE TANK AND HAVING ITS UPPER PORTION REMOVED TO ESTABLISH A DESIRED LIQUID LEVEL, EACH OF SAID LEVEL DEFINING PARTITIONS BEING SPACED FROM THE CONTIGUOUS SECTIONS CLOSING PARTITION TO PROVIDE A DOWNFLOW PASSAGEWAY TO THE ENTRANCE PORT OF THE ADJACENT DOWNSTREAM SECTION FOR MATERIAL OVERFLOWING THE LEVEL DEFINING PARTITION. 